Broke a Valve cover bolt

[The Buddha]

Broke the one in front ... right above the exhaust ports ... that one ... its stuck in the head and below the level of the head ... nothing to grip and twist ...  so how do i get it out ... and can I leave that one off ... the other 5 are good ...
Cool.
Srinath.

[davipu]

drill a hole and use a easy out

[sprint_9]

Can you get a drill in there?  If so maybe a one of those reverse drill bits will work, or drill it out just small enough so you dont ruin the threads then tap it out, youll have to be centered which will be the tough part since you will be tight on space.

[The Buddha]

I got no space to get anyhting in there wihtout taking the head off ...  I may try that dremel tool attachment thing ... even the cable extension thing wont fit I think ...
Cool.
Srinath.

[starwalt]

If the bolt broke off due to thread seizing, bad.

With the bolt head gone, if no thread seize, perhaps a little penetrant oil?  I have backed out many bolts this way because they are just hanging in there.

I bet you've got some thread seize though. Damn.

[The Buddha]

Yea threads are seized up ... the thing had loctite on all of the bolts ... meaning the cover has never been off ... 15K miles and 16 years and never had the cover off ... and guess what ... vajves were all in spec ... OK atleast had some clearance ... maybe too much ... but not tight ... I am thinking I'll just leave it ... 5 bolts should be enough ... and not like its oil tight anyway ... but that locations is likely to be the best of the lot ... left side end bolts are terrible ...
Cool.
Srinath.

[starwalt]

We're talking about this?



If so, you are probably right. I would use some of the silicone based sealant around it and go with it. Just let the next owner know about it so that when the engine is eventually torn down or removed, fix it then.

I picked up a good tip in the new issue of Road Racing World. The A.O.D. and N.O.T.B. wrenchers use wheel bearing grease to stick their gaskets on so that they don't do what I did most of Saturday - scrape and sand freakin gasket material off the right side of the engine and cover. Double Damn!

[The Buddha]

The blooming factory glues the gasket on with super glue on the engine ... not the outside cases ... Lousy ...
And that is the bolt that got broken ...And yup ... I am thinking of ignoring it post haste ...
Cool.
Srinath.

[JCH]

Thats how I knew mine had never had the valve clearances checked (14000 mi), because unless a stealer went through all the time to put more glue/gasket sealer around the entire thing, this had never been removed.

Two out of spec, but not more than one shim size

[gsJack]

I'd sure try it without the bolt if that one was broken.  Those are shoulder bolts and as such don't clamp down tight on the cover, when bolts are tight there is a specified gap left for the cover and gasket.  Gives proper squeeze on gasket.

If it leaks a bit, just put some green Permatex (non-hardening) on to stick gasket to cover.  Put some on the valve cover on the old 97 GS last time it was off to avoid getting new gasket.    :lol:  

When I broke a couple of the tiny cover bolts off on my 85 CB650SC a few years ago, I just stuck the broken bolts in the hole with the green Permatex.  Looked better that way and they were still there when I traded the bike on the first GS.    

[The Buddha]

I guess it will help keep it from collecting water in that dime sized hole ... I'll try that GSJack ... thanks.
Cool.
Srinath.

[denman]

try going up from the bottem that is a open ended bolt hole.   see ya.